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FLARES
TM
The strength of our JZ and KALDAIR product lines firmly establishes John Zink Company as a world leader in advanced flare systems for refining and petrochemical industries.
TABLE OF CONTENTS
Flare Selection Guide ....................................................................2 Smokeless Steam-Assisted Flares .................................................4 Efficient Air-Assisted Flares ...........................................................6 Community-Friendly Enclosed Flares .............................................8 Economical High-Pressure Flares ................................................10 Advanced Design Principles and Technologies.............................12 Superior Pilots, Pilot Monitors and Control Systems ....................14 Flare Test Center .........................................................................17
See page 14
See www.johnzink.com
See www.johnzink.com
See www.johnzink.com
OWB or DF Flare
Utility Flare
Liquid
Yes No
Is waste bio-gas?
Mixed
See www.johnzink.com
See page 4
Pit Flare
STEAMIZER Flare
Yes
Yes
No
No
Gas Pressure
Low
High
Yes
No
No
CONDAIR Flare
See Production Flare Brochure
STEDAIR Flare
See page 5
QS Series Flare
See page 5
Air-Assisted Flare
See page 6
POSEIDON Flare
Yes
No
MARDAIR Flare
Yes Yes
Gas Pressure
High
No
Are low noise and very low radiation and/or short flame length required? No
Are low purge and/or angled mounting and/or simultaneous smokeless LP flaring required?
Low
Yes
Yes
No
HYDRA Flare
See Production Flare Brochure
Yes No
Yes
Yes
No
Gas-Assisted Flare
See www.johnzink.com
FS INDAIR Flare
See Production Flare Brochure
STEAMIZER
The STEAMIZER flares ability to meet high-capacity smokeless burning requirements makes it the most in-demand flare tip in the world. The unique design induces large amounts of air into the core of some of the largest flare flames in the most difficult applications. The multiple port supersonic nozzle increases air eduction efficiency with reduced noise. A special muffler further reduces steam-injection noise. The STEAMIZER flares smokeless performance, low sound profile and reduced steam utility requirements make it an industry standard in smokeless flaring.
Steam Supply Converging-diverging supersonic nozzles increase air eduction efficiency with reduced noise. Technology detail on page 13. Steam Jets
FEATURES
Ultra-high smokeless capacity Low noise design Eliminates internal burning Reduces flame pulldown Low steam/gas ratio for smokeless flaring High turndown design Full-range flame stability Numerous options available for design flexibility
BENEFITS
Minimizes environmental/ community impact of flaring Extended tip life
Acoustic Performance
Smokeless Performance
Propylene smokeless flow rate (lb/hr) 90000 80000 70000 60000 50000 40000 49000 1st 2nd 3rd Generation of Steam Flare 63000 87000
Reduced utility costs Operational flexibility & reduced steam consumption Safe flaring operation Customized design to meet your specific process design and operational requirements
(dBA)
100 95 90 85 80 75 70
1st
2nd
3rd
The latest generation STEAMIZER flare provides superior smokeless performance in a low-noise design steam flare.
SKEC
PATENTED*
HALO, QS
PATENTED*
John Zinks single and multi-point steam-assisted flare tips use cost-effective designs to deliver smokeless operation and efficient steam consumption to processing and refining facilities.
STEDAIR
The rugged STEDAIR flare uses less steam than traditional steam-assisted flare systems and offers smokeless burning. The STEDAIR flares rugged yet simple Coanda design mitigates tip damage due to low flow burnback and operation under steam-loss conditions. The STEDAIR muffler delivers quiet operation.
FEATURES
Thick cast Coanda profiles utilized for steam injection Low steam/gas ratio for smokeless flaring No cooling steam required Low noise design
BENEFITS
Extended tip life
Minimizes environmental/ community impact of flaring Prevents internal ice buildup in freezing climates
SECONDARY AIR INDUCED AIR STEAM PRIMARY MIXING REGION COANDA PROFILE
STEDAIR SCHEMATIC
Steam ejected from the annular steam chamber follows the curve of the Coanda profile, mixing efficiently with the gas stream. Technology detail on page 13.
SKEC FLARE
Lowest steam-tohydrocarbon ratio of any multi-point flare available.
John Zinks demountable derrick structures allow multiple flares to be installed on a common structure. The demountable design allows the individual flare tips to be lowered to grade while the other flares remain safely in service. 5
LHLB
PATENTED*
The smokeless LHLB air-assisted flare system extends flare tip life while it minimizes the cost to dispose of difficult-to-burn gases. The LHLB flares annular swirl design mitigates the internal burning associated with the operation of large air-assisted flares at turndown while providing complete ignition of waste gases at high exit velocities. The low-maintenance, simple tip design has no moving parts, eliminating the potential freezing issues in cold climates associated with steam and steam-flow controls.
The annular swirl design of the LHLB flare prevents internal burning at low gas flow rates.
FEATURES
Annular design eliminates internal burning at low gas flow rates High smokeless capacity design Low noise design High turndown design Minimal air flow required for standby operation Low maintenance design
BENEFITS
Extended tip life
The unique annular LHLB flare design is the optimum design for high capacity air-assisted flares. Gas Flow
Air Flow
LH
The LH air-assisted flare is the most economical choice for small-to-moderate smokeless burning needs. The LH air-assisted flare tip lasts longer than traditional air flares and creates clean, upright flames with low radiation levels. The LH flare is ideal for application in systems with small-to-medium gas flow and also where high pressure is available.
AZDAIR
The AZDAIR flare delivers safe, smokeless operation in virtually all conditions - from maximum to minimum purge flow - without steam or support fuels. An efficient mixing head maximizes the systems gas-to-air interface. As a result, the AZDAIR flare creates a vertical, stiff, turbulent flame for a high degree of operating control.
FEATURES
Continuous air flow prevents overheating of flare tip Efficient gas/air mixing for smokeless operation High turndown design Minimal air flow required for standby operation Low maintenance design
BENEFITS
Extended tip life
FEATURES
Efficient mixing head design maximizes gas-to-air interface Mixing head design eliminates internal burning High turndown design Minimal air flow required for standby operation
BENEFITS
Reduced horsepower requirements for smokeless operation Extended tip life
The LH air-assisted flare is industrys most economical choice for small-to-moderate smokeless needs.
During normal operation of the AZDAIR flare, the fan operates at reduced capacity to conserve energy.
BLOWN AIR
LHTS, LS
The economical LHTS and LS flare designs meet low-to-moderate smokeless requirements for low-pressure flare systems while still enabling large emergency relief rates.
GAS STREAM MIXING ZONE GAS DUCT BLOWN AIR DUCT DETAIL OF MIXING HEAD
Relief gas moves up the AZDAIR flares annular duct and is mixed turbulently with air blown up the flares central duct.
Gas Exit
Mixing Zone
Exhaust Gases
Gas Inlet
The thin, tear drop-shaped gas distribution manifold of the fin plate burner provides a large open area for combustion air entrainment.
Each fin plate burner contains many individual fins to spread the flare gas into a thin film and optimize the gas/air mixing area.
The unique fluidic wind fence that surrounds the KEGF flare ensures an even air flow distribution across the entire burner cross-sectional area.
KEGF
The KEGF enclosed flare delivers smokeless flaring and concealed flames without steam or air assist. Its high-performance fin plate burners combust most every unsaturated gas and control emissions by reducing the flame temperature. The aerodynamic design of the flares fluidic wind fence eliminates hot spots caused by wind turbulence. Engineered to achieve high turndown ratio, the KALDAIR KEGF flare minimizes staging requirements. The flares unique, modular concept reduces site installation time and construction costs.
ZTOF
PATENTED*
The ZTOF flare is a natural-draft, staged-burner system that offers maximum smokeless combustion using air, steam or gas assist. The ZTOF flare provides cost-effective performance with high turndown ratio without burner adjustments or flare modifications. The proven enclosedflare technology demonstrates efficient waste gas destruction capacities in excess of 100 metric ton/hr for a variety of applications.
FEATURES
Smokeless operation of any hydrocarbon gas Operates with concealed flame High turndown ratio
BENEFITS
Minimizes environmental impact of conventional flares
FEATURES
BENEFITS
Smokeless flaring of low-pressure Reduced equipment costs, operating costs and maintenance costs gases without steam, air or other assist medium. Operates with concealed flame Minimizes environmental impact of conventional flares Reduced air emissions from combustion Provides a cost-effective, non-assisted design Safe flaring at locations within the plant Reduced installation costs
Staging system controls gas and Minimizes steam usage steam flow to burners Wind fence shields noise and radiation and directs air flow Unequalled performance and maintenance record Safe flaring at locations within the plant Can be selected with confidence for any enclosed ground flare application
The fin plate burner provides unassisted, highly efficient, smokeless flaring of highly unsaturated hydrocarbons such as ethylene and propylene.
The ZTOF flare design has been used to provide up to 200 ton/hr enclosed flare capacity in a dual unit enclosure design.
The natural draft design of the KEGF flare provides non-assisted, smokeless, non-visible flaring in a cost-effective enclosure design. 9
SMOKELESS.
visibility from ground-mounted systems. John Zinks high-pressure systems safely deliver the highest smokeless capacities of any flare from an unlimited number of burners. And, each of our flares employs John Zinks proprietary Flame Similarity Method to accurately predict smokeless performance, and conserve air and steam consumption. For more information about our clean-flare technologies, see page 12.
systems create short, smokeless flames with no gas, air or steam assist. A radiation fence is available to control the heat and flame
LRGO
PATENTED*
The LRGO multi-point flare system uses the energy in flared gas to achieve clean, economical combustion in high-pressure applications without steam or gas assist. The LRGO flare is proven to operate in excess of 10 years with minimal maintenance. This state-of-the-art flare induces air to a number of burning points for maximum smokeless combustion and unlimited turndown. A groundmounted configuration is easily concealed with a radiation fence. The LRGO flares specific burner spacing provides maximum crosslighting across the staged system.
The LRGO multi-burner flare system can be provided with radiation fences that completely shield the flame visibility and radiation at grade. The LRGO flare is provided with staging systems to ensure that short, smokeless flames are maintained over the full operating range of the flare.
FEATURES
High smokeless capacity without steam, air or other assist medium
BENEFITS
Minimizes environmental impact and reduces utility requirements for smokeless flaring
Radiation fence to control heat, flame Safe flaring at locations visibility and combustion air distribution within the plant Short flame length Optimal burner spacing ensures crosslighting to minimize the number of pilots required Ground mounted or elevated design Low visibility flare design Safe, stable burner ignition with minimal pilot fuel consumption
Rugged burner and radiation fence design Extended service life Low maintenance design Reduced operating and maintenance costs
10 10
FEATURES
Variable slot design provides infinite turndown
BENEFITS
100% smokeless operation without expensive staging systems Long flare tip life
No flame lick at low gas flow rates Rugged cast stainless steel Coanda nozzles Ideal for angled boom mounting
Shorter boom length required to meet radiation requirements Reduced operating cost (energy cost) Safe flaring operation
Flare gas exiting the INDAIR flare tip entrains and turbulently mixes 20 times its volume of air as it travels around the tulip-shaped Coanda profile.
AIR
H.P.
GAS
AIR
H.P.
GAS
Multi-stage design provides high turndown Reduced equipment and maintenance costs without the need for staging valves
The KMI flare utilizes multiple cast variable slot Coanda nozzles to provide 100% smokeless flaring in a rugged and durable flare tip design.
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THE WORLDS MOST ADVANCED FLARE TECHNOLOGY FROM JOHN ZINK COMPANY
John Zinks advanced flare technologies raise the bar on clean, efficient combustion and deliver the outstanding performance our customers expect. Through the renowned John Zink Research and Development Test Center, we employ empirical and proprietary design principles, sophisticated visualization tools, computerized modeling and full-scale testing to develop next-generation flare systems that can be put to work today.
FLAME SIMILARITY METHOD DELIVERS INDUSTRYS MOST ACCURATE SMOKELESS PERFORMANCE PREDICTIONS
John Zink developed the Flame Similarity Method (FSM) to quantitatively calculate whether a flame will smoke. The FSM relates the fundamental measures of the momentum of the air, steam and flared gas at the base of the flare tip to the smokeless capacity. The series of equations accurately predicts the smokeless performance of any flare, as long as the mass flow rates and momentum of the various gas constituents can be accurately determined.
THE FIN PLATE BURNER DELIVERS SUPERIOR COMBUSTION EFFICIENCY WITHOUT STEAM OR AIR ASSIST
John Zinks fin plate burner uses the industrys most advanced technology to stop emissions where they form, resulting in ultraefficient, clean combustion. The burner s fin shape acts as a flame stabilizer and enhances uniform combustion while the aerofoil-shape of its gas manifolds assists the entrainment of air. The overall effect is a matrix-style burner that produces an excellent flame with a wide turndown ratio.
Gas Spreads Into Fan Shaped Film Mixing Zone Gas Exit
Gas Inlet
1. The fin plate burner distributes the gas through a matrix of small holes adjacent to a shaped plate or fin. 2. As the gas exits the hole, it impinges on the plate and forms a thin film. 3. Air mixes effectively with the film to promote high-performance combustion.
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The multiple port supersonic nozzle produces the highest smokeless capacity of any single-point steam-assisted flare in the industry. The innovative design incorporates several smoke suppression strategies: increased perimeter, higher momentum, more combustion air, greater turbulence for mixing, dilution and chemical interaction by steam, and molding the flame to resist wind effects. The result is increased air eduction efficiency with reduced noise.
Steam Supply
The JZ supersonic steam nozzle is used to produce a high-efficiency, low-noise, steam-assisted flare design.
ANNULAR FLARE DESIGN PROVIDES SUPERIOR TIP LIFE FOR LARGE AIR FLARES
To understand and eliminate internal burning in air-assisted flare tips, John Zink Company performed an extensive study on the effects of wind during low flow rates. As a result, John Zink developed the patented annular flare tip. Waste gas exits the burner in one or more narrow annular jets, each surrounded by assist air. The annular flare design maximizes the perimeter area and extends tip life by minimizing internal burning.
The annular air-assisted flare provides a high smokeless capacity flare that is not susceptible to the internal burning problems that are common in many large diameter air-assisted flares.
Gas Flow Air Flow
Principles of Operation 1. Entrains and pre-mixes air into the hydrocarbon gas stream. 2. Ejects high-pressure gas radially outward from the annular slot at the base of the proprietary tulip-shaped flare tip. 3. Adheres gas to the Coanda profile and is diverted through 90 degrees. 4. Flame ignites just above the maximum diameter of the tulip for reliable ignition of the gas by external pilots. A protective film of hydrocarbon gas insulates the Coanda profile to prevent the flare tip from overheating.
COANDA PROFILE
GAS FILM
SLOT
HIGH PRESSURE GAS
13
WINDPROOF PATENTED*
The patented WINDPROOF flare pilot uses John Zinks advanced windshield design to withstand the most severe winds and rain with outstanding performance. Det Norske Veritas, the worlds most widely respected product verification and certification company, witnessed and verified that the WINDPROOF flare pilot remains lit under test conditions that exceeded 160 mph winds and 30 inch/hr of rainfall. WINDPROOF flare pilot delivers exceptional fuel efficiency and fuel flexibility with ultra-low maintenance.
ENERGY-EFFICIENT PILOTS
John Zinks energy-efficient pilots are engineered to stay lit in extreme wind and rain and eliminate re-ignition delays.
EEP-500
The EEP-500 pilot is dependable, affordable and completely adaptable to your current operations. Installed on hundreds of flares worldwide, the long-lasting pilot uses John Zinks advanced windshield design to ensure excellent ignition stability even in sub-zero climates. The EEP-500 pilot consumes less natural gas than conventional pilots, saving thousands of dollars in fuel per year, per pilot.
Patented WINDPROOF flare pilot.
14
SOUNDPROOF PATENTED*
The high-fidelity SOUNDPROOF flare pilot monitor uses an acoustic sensor to provide rapid, continuous and reliable pilot verification, even under the most intense weather conditions. SOUNDPROOF pilot monitor listens for the unique frequency generated by each pilot flame, then indicates the pilot flame status on a signal processor. The flame status is also registered by contacts, which can be used for remote monitoring.
SOUNDPROOF acoustic pilot monitoring system.
ZEUS
The ZEUS electric ignition device uses an air-cooled sparking tip to produce a high-energy discharge that instantly ignites the pilot. The ZEUS system monitors the EEP-500 pilot with solid-state electronics and controls that can be located up to 1,500 feet from the pilot.
KEP-100
The KEP-100 ignition system delivers a reliable spark within the pilot nozzle for instantaneous ignition. The KEP-100 remote control panel may be positioned up to 1,000 feet from the flare for easy access.
KEP-100
The KEP-100 flare pilot monitor and control system uses a DC signal for continuous flame monitoring. The system uses flame ionization to automatically detect and re-ignite the pilot flame in less than 30 seconds. The KEP-100 remote control panel may be positioned up to 1,000 feet from the flare for easy, at-grade maintenance during operation.
PILOTEYE 2000
The PILOTEYE 2000 pilot monitor uses infrared technology to provide fast, reliable pilot verification at grade. The PILOTEYE 2000 pilot monitor s dual wavelength technology is 40 times more sensitive than single wavelength detectors for reliable flame verification in adverse weather. The user-friendly interface can be customized to suit your specific monitoring and troubleshooting needs.
PILOTEYE 2000 infrared pilot monitor.
OTHER ACCESSORIES
John Zink offers a complete range of control systems to keep flares operating at maximum performance with long life and even longer maintenance intervals. Retractable thermocouples, steam controls, blower controls for air-assisted systems and explosionprevention systems are available for virtually every application.
ZOOM
The ZOOM monitor observes your flare for smoke and instantly adjusts steam levels to return the flare to smokeless operation. The savings from reduced steam consumption pays for the ZOOM system within months.
15
TECHNOLOGY
John Zinks range of capabilities is unmatched in the industry and provides a strong foundation for exploring the next generation of clean, economical combustion. Advanced problem solving is a hallmark of John Zink Company and has earned us a reputation for taking on the toughest challenges. Our Research and Development Test Center is the nerve center for exploring new technologies that address cleaner, more efficient combustion. Here, John Zink designs and tests JZ and KALDAIR flare performance for the worlds largest oil and gas production operations.
RESOURCES
With more than 300 engineers and technical experts, John Zink Company is recognized as the authority on combustion science and clean-air innovation. Our resources include cutting-edge research and development, industrial-scale testing, world-class manufacturing and around-the-clock service and support.
John Zink and its many brands of advanced combustion and pollution-control systems lead global industr y with a vast base of successfully operating systems.
16
John Zink Companys Research and Development Test Center is located on the campus of the companys world headquarters in Tulsa, Oklahoma.
17
USA
John Zink Company World Headquarters John Zink Company, LLC 11920 East Apache Tulsa, Oklahoma 74116 UNITED STATES OF AMERICA Tel: +1-918-234-1800 Fax: +1-918-234-2700
EUROPE
John Zink Europe Headquarters Koch Int. Luxembourg S..r.l. Zone Industrielle BNI Dudelange 3401 LUXEMBOURG Tel: +352-518991 Fax: +352-518611
ASIA-PACIFIC
John Zink Asia-Pacific Headquarters John Zink Asia-Pacific, a division of Koch Asia-Pacific, Inc. 7th Floor, KSS Gotanda Bldg. 21-8 Nishi-Gotanda 1-chome Shinagawa-ku, Tokyo 141-8538 JAPAN Tel: +81-3-5435-8551 Fax: +81-3-3491-3584
OTHER
Houston Los Angeles San Francisco Shelton, Conn. Calgary So Paulo Buenos Aires London Rotterdam Milan Madrid Shanghai Singapore Sydney
www.johnzink.com
* QS is covered by CA Patent Number 1227410. * LHLB is covered by one or more of the following Patents: U.S. Patent Number 5810575, 5846068. CA Patent Number 2226809. * SKEC, LRGO and ZTOF are covered by U.S. Patent Number 4652232 and CA Patent Number 1233107. * WindProof is covered by U.S. Patent Number 6702572 B2. Patents Pending in CA, CN, EPC, ES, SE, CH, GB, JP , KR, TR. * SoundProof is covered by one or more of the following Patents: U.S. Patent Number 5813849, CA Patent Number 2212403, EPC Patent Number 935098, DE Patent Number 69810072.7 and AU Patent Number 745552. Patents Pending in AU, JP , KR, KW, SA, VE.